Manual operated detail sander

ABSTRACT

A manually operated detail sander comprises a first plate, a second plate and a sheet of sanding material. The first plate has uniform thickness and includes first and second sides that define a sculpting profile. The second plate has the thickness of the first plate and has an ergonomic profile including an elongate fastening edge extending at least partially across and joined to the first side of the first plate. The sheet of sanding material extends across the second side of the first plate.

BACKGROUND

The present invention is directed to abrading devices and, moreparticularly, to manually operated detail sanders.

Many devices have been developed over the years to produce fine finisheson surfaces, such as on automobile panels or furniture facades. Manysuch devices comprise handheld platforms for stiffening sheets or stripsof sandpaper. Some of these devices comprise thick rectangular or squareblocks have protruding handles. These sanders provide large, rigidsurfaces that are well-suited for sanding large planar work areas. Assuch, the handles are typically thick and bulky to provide strength forrepeated, heavy usage. Other similar sanding devices have been developedfor producing detail finishes. These devices, too, often include thickhandles or large heads that inhibit application of the sander to allsurfaces. For example, thick handles, such as those disclosed in U.S.Pat. Nos. D612,222 to Ali et al. and 5,054,248 to Thayer, preventdelicate handling of the devices with fingers, thus inhibiting precisesanding. U.S. Pat. Nos. 4,730,430 to Petrovich and 3,699,729 to Garveyet al. disclose devices that provide elongate heads suitable forinsertion into small areas, but provide no gripping means to facilitatemanipulation. U.S. Pat. Nos. 4,694,618 to Eberhardt et al. and 4,977,712to Fisher et al. disclose devices having elongate sanding surfacescomprising strips of sanding paper in tension. These sanding surfacesare, however, flexible such that they inhibit delicate sanding. Althougheach of these devices provides a manually operated sander for particularapplications, none provides a device having dimensions suitable fordetail sanding of hard to reach or irregularly shaped surfaces whilealso being comfortable to manipulate.

SUMMARY

The present invention is directed to a manually operated detail sanderfor abrading surfaces. The detail sander comprises a first plate, asecond plate and a sheet of sanding material. The first plate hasuniform thickness and includes first and second sides that define asculpting profile. The second plate has the thickness of the first plateand has an ergonomic profile including an elongate fastening edgeextending at least partially across and joined to the first side of thefirst plate. The sheet of sanding material extends across the secondside of the first plate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a manually operated detail sander ofthe present invention having a head and a handle.

FIG. 2 shows a top view of the manually operated detail sander of FIG.1.

FIG. 3 shows a side view of the manually operated detail sander of FIG.1.

FIG. 4 shows a front end view of the manually operated detail sander ofFIG. 1.

FIG. 5 shows a close up view of callout 5 of FIG. 4 showing finishingmaterial adhered to the head by hook and loop fastener material.

FIG. 6 shows a side perspective view of an embodiment of a manuallyoperated detail sander having a handle that extends parallel beyond aperimeter of a sanding head.

FIG. 7 shows a side perspective view of an embodiment of a manuallyoperated detail sander having a handle positioned within a perimeter ofa sanding head.

FIG. 8 shows a top perspective view of an embodiment of a manuallyoperated detail sander having an ovaloid sanding head.

FIG. 9 shows a top perspective view of an embodiment of a manuallyoperated detail sander having a triangular sanding head.

FIGS. 10A and 10B show top perspective views of left-hand and right-handconfigurations of manually operated detail sanders having trapezoidalsanding heads with offset handles.

DETAILED DESCRIPTION

FIG. 1 shows a perspective view of manually operated detail sander 10 ofthe present invention. Detail sander 10 includes head 12, handle 14 andfinishing material 16. Head 12 includes handle side 18, planar side 20and head edge perimeter region 22. Handle 14 includes gripping surface24A, gripping surface 24B (FIG. 2), and handle edge perimeter region 26.Detail sander 10 comprises a device that is shaped to be easily grippedand precisely manipulated by a hand or fingers, while providing afinishing surface that can be easily inserted into small areas. Sander10 has an overall low profile and elongate and narrow shape toaccomplish these ends. In the embodiment shown if FIGS. 1-5, head 12 isrectangular, while handle 14 extends at an angle from handle side 18.Also, finishing material 16 is shown adhered to planar side 20 by hookand loop fastener material. Other embodiments with variations of thehead and handle are shown if FIGS. 6-10B.

FIG. 2 shows a top view of detail sander 10 of FIG. 1. Detail sander 10includes head 12 and handle 14. In the embodiment shown, head 12includes handle side 18, which forms a rectangular profile having frontside 28, rear side 30, right side 32 and left side 34. Planar side 20(FIG. 1) has an identical rectangular profile to that of handle side 18.Edge perimeter region 22 extends between handle side 18 and planar side20. Edge perimeter region 22 can be flat or rounded to facilitatemanufacture of head 12. Constructed as such, head 12 comprises a thin,plate-like structure.

From the side, handle 14 has thickness t₁, which produces a narrow shapeof sander 10. In one embodiment, thickness t₁ is approximately 0.25inches [in] (˜0.64 centimeters [cm]) thick. Head 12 also has a width W₁,which produces a narrow shape of sander 10. Width W₁ extends in thedirection of the minor axis of head 12. In one embodiment, width W₁ is1.5 in (˜3.8 cm). Head 12 has length L₁, which produces an elongateshape of sander 10. Length L₁ extends in the direction of the major axesof head 12 and handle 14. In one embodiment, length L₁ is approximately10 in (˜25.4 cm). These dimensions give sander 10 a geometry thatfacilitates manipulation and insertion into small areas. In particular,sander 10 has a high overall length to width ratio and a high overalllength to handle-thickness ratio. For example, embodiments of sander 10have a length to width ratio of approximately 6.5:1, and a length tohandle-thickness ratio of approximately 40:1 or greater.

Handle 14 is completely within the outline or profile of edge perimeterregion 22. Handle 14 extends completely across length L₁ of head 12 suchthat planar side 20 and finishing material 16 (FIG. 1) are fullysupported. In the embodiment shown, handle 14 extends across a middle ofwidth W₁ of head 12. In other embodiments, handle 14 may extend along anedge of head 12, such as right side 32 or left side 34. As is betterseen in FIG. 3, handle 14 extends generally longitudinally from handleside 18 of head 12.

FIG. 3 shows a side view of detail sander 10 of FIG. 1. Detail sander 10includes head 12, handle 14 and finishing material 16. In the embodimentshown, handle 14 includes gripping surface 24A, which forms a profilehaving grip 36, forward support 38, rear support 40 and contour 42.Gripping surface 24B (not shown) comprises an identical profile to thatof gripping surface 24A. Edge perimeter region 26 extends betweengripping surfaces 24A and 24B. Edge perimeter region 26 can be flat orrounded to facilitate manufacture of handle 14. Constructed as such,handle 14 comprises a thin, plate-like structure. Edge perimeter region26 includes planar fastening region 43.

Head 12 has thickness t₂, which produces a low height of sander 10. Inone embodiment, thickness t₂ is approximately 0.25 in (˜0.635 cm) thick.Head 12 has length L₁, which, as discussed above, is approximately 10 in(˜25.4 cm). Thus, the length to head-thickness ratio of sander 10 forthe embodiment shown is approximately 40:1. The thinness of head 12allows the fingers of an operator of sander 10 to come close to thesurface to be sanded, allowing for a better feel of the sandingoperation.

Grip 36 of handle 14 extends from handle side 18 of head 12 at angle α₁.In the embodiment shown, angle α₁ is approximately forty degrees. Grip36 extends along the minor axis of handle 14. Grip 36 is buttressed byforward support 38 and rear support 40, which comprise flared regions ofgrip 36 near head 12. For example, forward support 38 is flared fromgrip 36 at approximately twenty degrees. As such in one embodiment angleα₂ is approximately one-hundred-sixty degrees. Similarly, support 40flares rearward to the back of head 12. Supports 38 and 40 extend thewidth of grip 36 across head 12 without unduly increasing the height ofsander 10 across its entire length.

Handle 14 extends at such angles to provide an ergonomic lever foroperators of sander 10. Extension of grip 36 allows a tip portion ofhead 12 away from grip 36 to be easily inserted into a small orifice orother such cramped area. Other angles that extend the tip of head 12away from grip 36 can be used. Contour 42 provides ergonomic shaping togrip 36 to provide comfort to operators of sander 10. The combination ofangled grip 36 and contour 42 allow sander 10 to be easily manipulatedwith a hand or with only the fingers of a hand.

Grip 36, support 38 and support 40 form planar fastening region 43 ofedge perimeter region 26. Fastening region 43 extends across the entirelength of head 12 to add rigidity. As such fastening region 43 extendsin the direction of the major axis of handle 14. Fastening region 43prevents head 12 from flexing so that sander 10 more readily keepsfinishing material 16 in contact with a surface to be sanded.

FIG. 4 shows a front end view of manually operated detail sander 10 ofFIG. 1. Handle 12 extends straight out from head 14 such that rightangles are formed between handle side 18 of head 12 and grippingsurfaces 24A and 24B of handle 14. Handle 14 has height H₁. Height H₁extends along the minor axis of handle 14. In one embodiment, height H₁is approximately 5 in (˜12.7 cm). The height of handle 14 is selected tofacilitate manipulation of head 12. For example, the taller handle 14is, or the larger angle α₁ is, the easier it becomes to tilt head 12,thus making adjustment of sander 10 easier.

Finishing material 16 is affixed to planar side 20 of head 12. Planarside 20 is flat to allow finishing material 16 to flushly contact thesurface to be sanded. As discussed above, handle 14 stiffens head 12such that finishing material 16 remains in contact with the surface tobe sanded during operation. Accordingly, finishing material 16 isrigidly adhered to planar side 20 of head 12 to resist deformation. Inone embodiment, finishing material 16 is glued or otherwise secured withadhesive to planar side 20. In other embodiments, finishing material 16is secured to planar side 20 using fastener material, as discussed withreference to FIG. 5. In other embodiments, a layer of foam can bepositioned between finishing material 16 and planar side 20.

FIG. 5 shows a close up view of callout 5 of FIG. 4 showing finishingmaterial 16 adhered to head 12 by interaction of hook and loop fastenermaterial. The hook and loop fastener material includes hook material 44and loop material 46. Finishing material 16 includes backing 48 andabrasive material 50. Loop material 46 is bonded to planar surface 30such as with an adhesive. Likewise, hook material 44 is bonded tobacking 48 of finishing material 16. Additionally, abrasive material 50is bonded to backing 48 via a bonding agent. Abrasive material 50comprises sand or other granules typically used to abrade material.Backing 48 and abrasive material 50 comprise typical sand paper or othersuch similar products. Hook material 44 and loop material 46 comprisetypical fabric hook and loop fastener material, such as Velcro®, whichis a registered trademark of Velcro Industries.

FIG. 6 shows a side perspective view of manually operated detail sander52 having handle 54 that extends parallel beyond a perimeter of sandinghead 56. Head 56 comprises a rectangular head similar to the headdescribed with respect to FIGS. 1-5, including a layer of finishingmaterial and edge perimeter region 57. Handle 54 comprises grip 58 andsupport 60. Handle 54 and head 56 comprise plate-like structures joinedalong a flat fastening region of edge perimeter region 57. In oneembodiment, each plate is approximately 0.25 in (˜0.635 cm) thick.

Grip 58 comprises an elongate handle-member having a generallytrapezoidal shape. First end 62 of grip 58 is positioned near mid-point64 of head 56, while second end 66 of grip 58 extends beyond edgeperimeter region 57 of head 56. Grip 58 extends along a major axis ofhandle 54, generally parallel to the major axis of head 56. Support 60extends from the first end of grip 58 toward the edge of head 56 atfirst end 62. As such, handle 54 extends across the entire length ofhead 56. Thus, handle 54 can be used to press the entirety of head 56into the surface to be sanded while keeping head 56 rigid. However,support 60 is tapered such that the height of first end 62 is reduced tofacilitate insertion of sander 52 into tight areas. In the embodimentshown, head 56 has a length of approximately 8 in (˜20.3 cm) from firstend 62 to second end 66, the length of handle 54 has a length in thesame direction of approximately 12 in (˜40.6 cm), and the width of head56 is approximately 1.5 in (˜3.8 cm).

FIG. 7 shows a side perspective view of manually operated detail sander68 having handle 70 positioned within a perimeter of sanding head 72.Head 72 comprises a rectangular head similar to the head described withrespect to FIGS. 1-5, including a layer of finishing material and edgeperimeter region 74. Handle 70 comprises grip 76 and contours 78A and78B. Handle 54 and head 56 comprise plate-like structures joined along aflat fastening region of edge perimeter region 74. In one embodiment,each plate is approximately 0.25 in (˜0.635 cm) thick.

Grip 76 comprises an elongate handle-member having a generallyrectangular shape that extends across head 72 from first end 80 tosecond end 82. Grip 76 extends along a major axis of handle 70,generally parallel to the major axis of head 72. The height H₂ of handle70 is short compared to length L₂ of head 72. In one embodiment, heightH₂ is approximately 1.5 in (˜3.8 cm) and length L₂ is approximately 20in (˜50.8 cm), giving rise to a length to width ratio of overapproximately 13:1. Sander 68 also has a length to thickness ratio ofapproximately 80:1. The width of head 72 is approximately 1.5 in (˜3.8cm). Contours 78A and 78B provide handle 70 with an ergonomic grippingshape. For example, contours 78A and 78B accommodate the palm of a handwhen gripped by an operator.

FIG. 8 shows a top perspective view of manually operated detail sander84 having ovaloid sanding head 86 and handle 88. Handle 88 includescenter grip 90 and supports 92A and 92B. Head 86 includes center portion94, first rounded end 96A, second rounded end 96B and edge perimeterregion 98. Handle 88 and head 86 comprise plate-like structures joinedalong a flat fastening region of edge perimeter region 98. In oneembodiment, each plate is approximately 0.25 in (˜0.635 cm) thick.

Handle 88 comprises an isosceles trapezoid-shaped plate having a firstflat edge that runs along center grip 90 parallel to head 86, a secondflat edge that runs along center grip 90 and supports 92A and 92Bagainst head 86, and oblique edges that extend from the first flat edgeto head 86 along supports 92A and 92B. Handle 88 extends a shortdistance straight out from head 86 at a right angle. In one embodiment,handle 88 is approximately 1.5 in (˜3.8 cm) tall. Thus, handle 88provides grip for manipulating sander 84, but is tapered to facilitateworking with rounded ends 96A and 96B of head 86.

Head 86 comprises an ovaloid-shaped plate having two straight edges thatextend along center portion 94 and two rounded edges at rounded ends 96Aand 96B, respectively, that connect the two straight edges. Head 86 hasan overall length L₃. In one embodiment, L₃ is approximately 6 in (˜15.2cm) such that the length to thickness ratio of sander 8 is approximately24:1. The radii R of rounded ends 96A and 96B are approximately half ofwidth W₃ of head 86. In one embodiment, W₃ is approximately 1.5 in (˜3.8cm) such that R is approximately 0.75 in (˜1.9 cm).

FIG. 9 shows a top perspective view of manually operated detail sander100 having triangular sanding head 102 and handle 104. Head 102 andhandle 104 comprise plate-like structures similar to those of otherembodiments, each being approximately 0.25 in (˜0.635 cm) thick. Edgeperimeter region 106 of head 102 comprises a triangle, having vertex 108and base 110. Edge perimeter region 112 of handle 104 comprises aright-angled trapezoid having parallel base sides 114 (of which only oneis shown in FIG. 9), an oblique-angled side extending across head 102and a right-angled side connecting parallel sides 114. Theoblique-angled side of handle 104 extends from vertex 108 of thetriangle to a center point of base 110 of the triangle. As such,parallel base sides 114 of handle 104 extend away from head 102 at anangle. Thus, handle 104 allows vertex 108 of head 102 to be easilyinserted into tight areas. In the embodiment shown, head 102 isapproximately 6 in (˜15.2 cm) long and approximately 1.5 in (˜3.8 cm)wide at base 110, and handle 104 is approximately 1.5 in (˜3.8 cm) talland approximately 8 in (˜20.3 cm) long from the oblique-angled side tothe right-angled side.

FIGS. 10A and 10B show top perspective views of manually operated detailsanders 116A and 116B having left-hand and right-hand configurations,respectively, of trapezoidal sanding heads with offset handles. Detailsander 116A includes head 118A and handle 120A. Head 118A comprises aright-angled trapezoid having oblique-angled side 122A, right-angledside 124A and parallel base sides 126A and 128A. Similarly, handle 120Acomprises a trapezoid having oblique-angled side 130A, end side 132A andparallel base sides 134A and 136A. Detail sander 116B includes analogouselements bearing the same reference numerals with the designation “B.”

In one embodiment, right-angled side 124A of head 118A is approximately1.5 in (˜3.8 cm), side 126A is approximately 6 in (˜15.2 cm), and side126B is approximately 4.5 in (˜11.4 cm), while side 136A of handle 120Ais approximately 12 in (˜30.5 cm), side 134A is approximately 8 in(˜20.3 cm), and side 130A is approximately 4.5 in (˜11.4 cm).

Oblique-angled side 130A of handle 120A is positioned across head 118A.Oblique-angled side 130A abuts right-angle side 124A and base side 128Aof head 118A. Oblique-angled side 130A extends toward the intersectionof base side 126A and oblique-angled side 122A at point 138A of head118A at angle α₃. In one embodiment, angle α₃ is approximately tendegrees. Accordingly, angle α₄ shown in FIG. 10B is also approximatelyten degrees. Oblique-angled side 122A of head 118A positions point 138Aalong base side 126A. Handle 120A is directed toward point 138A. Thus,an operator of sanders 10A and 10B have the benefit of having a pointedsanding head, similar to that of the triangular sanding head of FIG. 9,as well as the benefit of straight edge sanding head, similar to that ofthe rectangular sanding head of FIGS. 1-4. The orientation of handle120A toward point 138A allows the operator feel the orientation of head118A, while also providing a suitable feel for base side 126A.

The present invention provides a detail sander that can be fabricatedwith a variety of configurations. Each sander is comprised of two thinplates, e.g. “a smooth, flat, relatively thin, rigid body of uniformthickness” as plates are commonly defined by dictionaries. Althoughdescribed as two separate plates that are joined together, each sandercan be formed as a single piece. For example, each sander can be formedof wood material wherein the two plates are bonded together with a glueor adhesive, or each sander can be formed of a plastic material whereinthe two plates are simultaneously formed during an injection moldingprocess.

Additionally, the disclosed embodiments describe various sanding headsand handles having different configurations in specific combinations.Each sanding head has an edge perimeter region defining a sculptingprofile, while each handle has an edge perimeter region defining anergonomic profile. However, in other embodiments, the sanding head ofone described embodiment may be used in combination with a handle ofanother described embodiment. For example, the triangular sanding headof FIG. 9 may be provided with an angled handle of FIG. 1 or a straighthandle of FIG. 6. The various configurations have high overall length tothickness ratios, which permit the sanders to be inserted in small,confined spaces while giving operators improved feel of the sandingoperation.

While the invention has been described with reference to an exemplaryembodiment(s), it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment(s) disclosed, but that theinvention will include all embodiments falling within the scope of theappended claims.

1. A manually operated detail sander comprising: a first plate ofuniform thickness having first and second sides that define a sculptingprofile; a second plate having the thickness of the first plate andhaving an ergonomic profile including an elongate fastening edgeextending at least partially across and joined to the first side of thefirst plate; and a sheet of finishing material extending across thesecond side of the first plate.
 2. The manually operated detail sanderof claim 1 wherein the sheet of finishing material extends rigidlyacross the second side of the first plate.
 3. The manually operateddetail sander of claim 1 wherein the sheet of sanding material issecured to the second side of the first plate by hook and loop fastenermaterial.
 4. The manually operated detail sander of claim 1 wherein thesculpting profile defines a first major axis and a first minor axisextending along a length and width of the first plate, respectively,such that a ratio of the length to the width is approximately 5:1 orhigher.
 5. The manually operated detail sander of claim 4 wherein theratio of the length of the first plate to the thickness of the firstplate is approximately 20:1 or higher.
 6. The manually operated detailsander of claim 4 wherein the fastening edge of the second plate extendsacross an entirety of the length of the first plate along a joinedregion.
 7. The manually operated detail sander of claim 4 wherein thefastening edge of the second plate extends across an edge of thesculpting profile of the first plate.
 8. The manually operated detailsander of claim 4 wherein the ergonomic profile of the second platedefines a second major axis and a second minor axis extending along alength and a width of the second plate, wherein the second major axisextends at an oblique angle to the first major axis.
 9. The manuallyoperated detail sander of claim 4 wherein the ergonomic profile of thesecond plate defines a second major axis and a second minor axisextending along a length and a width of the second plate, wherein thesecond minor axis extends at an oblique angle to the first major axis.10. The manually operated detail sander of claim 4 wherein the ergonomicprofile of the second plate defines a second major axis and a secondminor axis extending along a length and a width of the second plate,wherein the second major axis extends parallel to the first major axis.11. The manually operated detail sander of claim 4 wherein the sculptingprofile defines a triangular region.
 12. The manually operated detailsander of claim 4 wherein the sculpting profile defines an oval region.13. The manually operated detail sander of claim 4 wherein the sculptingprofile of the first plate surrounds the second plate.
 14. A manuallyoperated abrading tool comprising: a head comprising: an elongate planarfinishing side; an elongate planar handle side, wherein the finishingside and the handle side have matching first profiles; and a first edgeperimeter region extending between the finishing side and the handle todefine a thickness; a handle comprising: a pair of elongate planargripping surfaces having matching second profiles; a second edgeperimeter region extending between the elongate planar gripping surfacesand having the thickness of the first edge perimeter region; and aplanar fastening region along the second edge perimeter region securedto the elongate planar handle side of the head; and a strip of abrasivefinishing material rigidly secured to the elongate planar finishing sideof the head.
 15. The manually operated abrading tool of claim 14 whereinthe strip of abrasive finishing material is secured to the finishingside of the elongate planar head by hook and loop fastener material. 16.The manually operated abrading tool of claim 14 wherein the matchingfirst profiles define a first major axis and a first minor axisextending along a length and width of the matching first profiles,respectively, such that a ratio of the length to the width isapproximately 5:1 or higher.
 17. The manually operated abrading tool ofclaim 16 wherein a ratio of the length of the matching first profiles tothe thickness of the edge perimeter regions is approximately 20:1 orhigher.
 18. The manually operated abrading tool of claim 16 wherein thematching second profiles define a region having a second major axis anda second minor axis, wherein the second major axis extends at an obliqueangle to the first major axis.
 19. The manually operated abrading toolof claim 16 wherein the matching second profiles define a region havinga second major axis and a second minor axis, wherein the second majoraxis extends parallel to the first major axis.
 20. The manually operatedabrading tool of claim 16 wherein the matching first profiles define aregion having a shape selected from the group consisting of a triangularregion and an oval region.